Polymer/composite firearms and a process for strengthening polymer/composite firearms

ABSTRACT

A strengthened firearm includes at least one metal/composite material formed into at least one firearm component, and a polymer/composite material combined with the at least one firearm component. The metal/composite material replaces the polymer/composite material in a specific area or component of the firearm that may be weak or tend to fail earlier than other areas or components of a polymer/composite firearm. The method of combining the multiple materials allows for additional strength in the firearm.

BACKGROUND OF THE INVENTION

The present invention relates to firearms and, more particularly, tostrengthened polymer/composite firearms and methods for strengtheningthe same.

Polymer/composite firearms are used because they cost less and are lightweight. Currently, there are weak or commonly known failure areas inpolymer/composite firearms and firearms components. The components arenot durable and sacrifice strength and the ability to withstand theextreme pressures and stresses created upon firing a round of ammunitionin exchange for the lighter weight.

As can be seen, there is a need for a process that strengthenspolymer/composite firearms in areas that are weak or commonly failwithout losing the positive properties of a polymer/composite firearm.

SUMMARY OF THE INVENTION

In one aspect of the present invention, a strengthened firearm comprisesat least one metal/composite material formed into at least one firearmcomponent; and a polymer/composite material combined with the at leastone firearm component.

In another aspect of the present invention, a method for strengtheningpolymer/composite firearms comprises forming at least onemetal/composite material to a desired shape of at least one firearmcomponent; inserting the at least one metal/composite material in apolymer/composite firearm mold; and combining the at least onemetal/composite material and a polymer/composite material into astrengthened firearm.

These and other features, aspects and advantages of the presentinvention will become better understood with reference to the followingdrawings, description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary embodiment of the presentinvention in use;

FIG. 2 is a detail perspective view of an exemplary embodiment of thepresent invention omitting multiple parts for illustrative clarity;

FIG. 3 is an exploded view of an exemplary embodiment of the presentinvention;

FIG. 4 is a perspective view of a stock buffer tube mount of anexemplary embodiment of the present invention;

FIG. 5 is a side view of the stock buffer tube mount of an exemplaryembodiment of the present invention;

FIG. 6 is a top view of the stock buffer tube mount of an exemplaryembodiment of the present invention;

FIG. 7 is a perspective view of a barrel receiver of an exemplaryembodiment of the present invention;

FIG. 8 is a side view of a barrel receiver of an exemplary embodiment ofthe present invention; and

FIG. 9 is a top view of a barrel receiver of an exemplary embodiment ofthe present invention.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of the best currently contemplatedmodes of carrying out exemplary embodiments of the invention. Thedescription is not to be taken in a limiting sense, but is made merelyfor the purpose of illustrating the general principles of the invention,since the scope of the invention is best defined by the appended claims.

Broadly, an embodiment of the present invention provides a strengthenedfirearm and method. The strengthened firearm may include at least onemetal/composite material formed into at least one firearm component, anda polymer/composite material combined with the at least one firearmcomponent. The metal/composite material replaces the polymer/compositematerial in a specific area of the firearm that may be weak or tend tofail earlier than other areas of a polymer/composite firearm. The methodof combining the multiple materials allows for additional strength inthe firearm.

In composite/polymer firearms there are multiple areas or componentsthat tend to fail earlier than other areas. The polymer used for moldingmay be a glass, Kevlar or carbon fiber filled nylon, glass, Kevlar orcarbon fiber filled polyetherimide. The body may be molded out of anynumber of plastics that give the desired performance characteristicswhether filled or unfilled. A process to strengthen these areas orcomponents may increase the life span of the firearm. The process forstrengthening polymer/composite firearms as herein described refers tospecific components of a firearm. However, other components may bedesigned in a similar manner within the scope of the present invention.

As is illustrated in FIGS. 1 through 9, an exemplary firearm 10 mayinclude a stock/buffer tube mount 14, a polymer/composite receiver 12, abarrel receiver 20 and a polymer/composite upper receiver 22. Thestock/buffer tube mount 14 may have a lower portion and may include astock/buffer tube thread receiver insert joint 18 and a tube mountretainment feature 28. The stock/buffer tube thread receiver insertjoint 18 may be attached to the stock/buffer tube mount 14. In certainembodiments, the stock/buffer tube thread receiver insert joint 18 maybe attached to the lower portion of the stock/buffer tube mount 14 as isshown in FIGS. 4 through 6. The stock/buffer tube mount 14 may be madefrom a metal material, a composite material, or a metal/compositematerial. The stock/buffer tube mount 14 may then become ametal/composite firearm component. The metal material may be aluminumalloys, steel, titanium and the like. The composite material mayinclude, but is not limited to, carbon fiber, Kevlar, fiberglass and thelike.

In certain embodiments, at least one metal/composite material with thetube mount retainment feature 28 may be manufactured to the desiredshape of the specific at least one firearm component of the specificfirearm model. The at least one firearm component may be inserted into afirearm mold. The polymer/composite material may then be injected aroundthe at least one metal/composite component. The specific at least onefirearm component may then have the desired and designed strengthincrease over just a strictly polymer/composite firearm model. The overmolded at least one metal/composite component has the designed tubemount retainment feature 28 that may allow plastic to flow into the tubemount retainment feature 28 areas so that the at least one firearmcomponent may be held in place and the desired strength may be achieved.The designed tube mount retainment feature 28 shows a specific style inFIGS. 3 through 5. However, other styles such as undercuts, slots, holesand the like, may be used in a similar manner within the scope of thepresent invention. A stock/buffer tube over molding area 16 along theexemplary firearm 10 may be where the stock/buffer tube thread receiverinsert joint 18 may be over molded. A serial number plate 24 may bedisposed along the stock/buffer tube thread receiver insert joint 18.

The barrel receiver 20 may be another part of the firearm that may needadditional strength. Similar to the stock/buffer tube mount 14, thebarrel receiver 20 may require a barrel receiver retainment feature 26.The barrel receiver 20 may be made from a metal/composite material orthe like. The barrel receiver retainment feature 26 may retain thebarrel receiver 20 so that polymer/composite material may be injectedaround the metal/composite part.

Instead of taking material away from the firearm to reduce weight andgain the advantages of plastic properties of polymer/composite firearms,the present process may replace the necessary components altogether witha stronger material, such as a metal material, a composite material or ametal/composite material, that covers a large surface area by havingthis stronger material added to specific targeted components of thepolymer/composite firearm that may cause early failure of thepolymer/composite firearm. When the strengthen firearm may be used, theenergy of a recoil of the bolt may be spread out along a large surfacearea across the metal material, composite material or metal/compositematerial. By spreading out the energy, the at least one firearmcomponent may have an extended life span due to less fatigue.

In certain embodiments, the method of combining the metal/compositematerial and the polymer/composite material may involve over molding,insert molding, using a retaining feature such as fastener, like in asnap type of fastening and the like, or gluing the metal/compositecomponent to any area of needed strength along the firearm. The presentprocess may be used on an AR-15 as shown in the Figures, but may also beused on any firearm. The present process may be used on receivers,buffer tube mounts and any other part of the firearm that may needstrengthening. In alternate embodiments of the invention, the sameprocess may be used for medical devices, over molding cell phone metalbases, electrical bus ways for electrical distribution and the like.

It should be understood, of course, that the foregoing relates toexemplary embodiments of the invention and that modifications may bemade without departing from the spirit and scope of the invention as setforth in the following claims.

What is claimed is:
 1. A strengthened firearm comprising: at least onemetal/composite material formed into at least one firearm component; anda polymer/composite material combined with the at least one firearmcomponent.
 2. The strengthened firearm of claim 1, wherein the at leastone firearm component is a stock/buffer tube mount.
 3. The strengthenedfirearm of claim 1, wherein the at least one firearm component is abarrel receiver.
 4. The strengthened firearm of claim 1, wherein thepolymer/composite material is combined with the at least one firearmcomponent by over molding.
 5. The strengthened firearm of claim 1,wherein the polymer/composite material is combined with the at least onefirearm component by insert molding.
 6. The strengthened firearm ofclaim 1, wherein the polymer/composite material is combined with the atleast one firearm component by fastening the at least one firearmcomponent to the polymer/composite material.
 7. The strengthened firearmof claim 1, wherein the polymer/composite material is combined with theat least one firearm component by gluing the polymer/composite materialto the at least one metal/composite component.
 8. A method for creatinga strengthened polymer/composite firearm comprising: forming at leastone metal/composite material to a desired shape of at least one firearmcomponent; inserting the at least one metal/composite component in apolymer/composite firearm mold; adding a polymer/composite material intothe polymer/composite firearm mold; and combining the at least onemetal/composite component and the polymer/composite material into astrengthened firearm.
 9. The method of claim 8, wherein combining the atleast one metal/composite material to a polymer/composite materialcomprises over molding the polymer/composite material over themetal/composite part.
 10. The method of claim 8, wherein combining theat least one metal/composite material to a polymer/composite materialcomprises insert molding the polymer/composite material over the atleast one metal/composite part.
 11. The method of claim 8, whereincombining the at least one metal/composite material to apolymer/composite material comprises fastening the polymer/compositematerial to the at least one metal/composite part.
 12. The method ofclaim 8, wherein combining the at least one metal/composite material toa polymer/composite material comprises gluing the polymer/compositematerial to the at least one metal/composite part.
 13. The method ofclaim 8, wherein the at least one metal/composite material is formed inthe shape of a stock/buffer tube mount.
 14. The method of claim 8,wherein the at least one metal/composite material is formed in the shapeof a barrel receiver.
 15. The method of claim 8, wherein the at leastone metal/composite part comprises three metal/composite parts.